2002 Volvo S60 AWD Turbo Cranks but not starting

[Buckone]

It was the fine teeth that mate with the shaft itself. It almost looked rusted or like some corrosion. The shaft was in perfect shape. The mechanic told me he had the part come from the Volvo dealer. When the guy delivered it he asked to see the other part. He said he had never seen one strip out before.

[precopster]

First time this type of failure has been reported here on Matthews and I've been lurking here for about 4 years.

I would be using anti-seize on it the 2nd time around to exorcise any rust/corrosion demons.

[gizmokip]

I'm gonna pull my HB and look at mine. How much did that gear cost you to replace?

[Buckone]

I can't give you an exact answer on the cost since a lot of other things were done trouble shooting the problem, but... The "timing belt crank pulley" (part no. 3531531) cost $145.54 through the shop. Ebay has it for $70. I can tell you it's not an easy or cheap job since the timing has to be reset. You'll need a special tool to lock things in place to do it. Here is pic of what stripped out.

[gizmokip]

Yes and I guess it can't be that rare. Mine makes number two. Barely two weeks after you figured yours out huh? I did a LOT of work on mine up until i found this topic about your car. It was at a point we're I could turn it by hand. Now its stuck and i cant wiggle it out. Did the dealer happen to say what they used to get it off? Although from first look I don't think I'll be as lucky as you about the crankshaft itself.

[Buckone]

All the repair shop said was that it "slipped right off." They may have used a gear puller, but it didn't take much effort.

[precopster]

This is an area the factory should apply anti-seize.

I can see snowy regions where salt is used on the road being a more likely spot for this to occur. Was this the case in both your situations?

[Buckone]

I wasn't the original owner, but it was in the family. The car spent most of its life in KY and WV. Neither of which use a lot of salt, but both get their fair share of wet/snowy weather. This part isn't really that exposed. However, it does look like moisture was a problem given the corrosion. The mechanic said when he installed the new gear he put a little grease on it to keep the moisture out.